Non-destructive testing of composites

Composite materials combine low weight with high performance, but their structure means that defects and damage can be difficult to detect. Delamination, porosity, cracks, impact damage and flaws in joints may be present beneath the surface without being visible in a standard visual inspection. Non-destructive testing makes it possible to examine the internal condition of a component while preserving it for continued use or further analysis.

RISE combines test methods, test set-ups and analysis based on the material, geometry, manufacturing process and the question to be answered. The results are turned into technically useful data for purposes such as quality control, damage assessment, process development, maintenance planning and service life assessment.

Non-destructive testing is also a key enabler of circular material flows and circular strategies such as recycling, reuse and remanufacturing. By verifying the condition of a component, decisions about a second life can be based on facts rather than assumptions. This reduces the risk of both unnecessary scrapping and unsafe reuse.

Examples of methods and applications

• Ultrasound for detecting and mapping delamination, porosity and flaws in joints.
• X-ray and computed tomography (CT) for two- and three-dimensional visualisation of internal structures and defects.
• Digital image correlation and digital volume correlation (DIC/DVC) for measuring deformation and damage progression on the surface and within the material volume.
• Acoustic emission for monitoring when and how damage initiates and develops under load.
• Thermography for fast, contactless detection of near-surface anomalies through analysis of heat flows.
• Shearography for contactless detection of defects in laminates and sandwich structures.

Customer benefits throughout the component life cycle

• Production: detect defects early, verify joints and process quality, and reduce scrap and rework.
• Operation and maintenance: inspect with limited disassembly, monitor damage progression and plan maintenance based on actual condition.
• Repair: locate damage, define the repair area and verify the result of the repair.
• Circular strategies: qualify components for reuse or remanufacturing and create traceable decision data for the next life cycle.

Our offer

RISE provides support from the initial decision question through to completed testing, analysis and documentation. An assignment may include:

• Defining the test question and acceptance criteria.
• Selecting and combining suitable NDT methods.
• Designing test set-ups for material samples, joints, parts or complete structures.
• Performing inspection and measurement in a laboratory environment or, where conditions allow, close to the customer’s process or component.
• Analysing, visualising and interpreting measurement data.
• Linking observed indications to mechanical behaviour and damage progression.
• Providing a basis for decisions on quality, repair, maintenance, reuse, remanufacturing or recycling.
• Method development, verification and knowledge transfer tailored to the customer’s application.